Blowout preventer installation and removal devices and related methods

ABSTRACT

A blowout preventer (BOP) installation and removal device, includes: a carriage for supporting a BOP assembly, the BOP assembly having a BOP axis; the carriage being mounted on a linear actuator that has a translation axis that is parallel to the BOP axis; and a rotator mounted to the carriage and connectable to the BOP for rotating the BOP about the BOP axis. A combination of a BOP assembly mounted to the carriage of the BOP installation and removal device with the rotator connected to the BOP and the BOP axis parallel to the translation axis. A rotation of the BOP aligns the axis of the BOP with the axis of the well. A method of using the BOP installation and removal device including installing a BOP assembly on a well.

TECHNICAL FIELD

This document relates to blowout preventer installation and removal devices and related methods.

BACKGROUND

Blowout preventers (BOP) are installed on wellheads to prevent expulsion of pressurized well fluids and loss of well control. For vertical applications, BOPs are typically installed using cranes or drawworks.

SUMMARY

A blowout preventer (BOP) installation and removal device, comprising: a carriage for supporting a BOP assembly, the BOP assembly having a BOP centerline axis; the carriage being mounted on a linear actuator that has a translation axis that is parallel to the BOP axis; and a rotator mounted to the carriage and connectable to the BOP for rotating the BOP about the BOP centerline axis.

A combination is disclosed comprising a BOP assembly mounted to the carriage of the BOP installation and removal device with the rotator connected to the BOP and the BOP axis parallel to the translation axis.

A method of using the BOP installation and removal device further comprising installing a BOP assembly on a well.

A blowout preventer (BOP) installation and removal device is disclosed, comprising: a BOP assembly mounted on a carriage, the BOP assembly having a BOP axis; the carriage being mounted on a linear actuator that has a translation axis that is parallel to the BOP axis; a rotator mounted to the carriage and connected to the BOP for rotating the BOP about the BOP centerline axis; and the linear actuator being mounted on a loader mounting part, such as a quick connector jib boom, with a pivot actuator connected to pivot the linear actuator, relative to the loader mounting part, about a pivot axis perpendicular to the translation axis.

In various embodiments, there may be included any one or more of the following features: The BOP installation and removal device is mounted on a loader arm of a loader. The linear actuator is mounted on a loader mounting part, such as a quick connector jib boom, with a pivot actuator connected to pivot the linear actuator, relative to the loader mounting part, about a pivot axis perpendicular to the translation axis. The loader mounting part or quick connector jib boom is mounted on a loader arm of a loader. The pivot axis is horizontal to a ground reference surface below the loader. The loader mounting part or quick connector jib boom is positioned above the linear actuator in use. The carriage further comprises one or more collars that are coaxial with the BOP centerline axis and form a seat for one or more annular flanges of the BOP assembly. The carriage is mounted to the linear actuator via one or more rails. One or more of the linear actuator and rotator each comprise a screw jack. A controller is connected to send control signals to one or more components of the BOP installation and removal device. Installing comprises: aligning the BOP axis with a well axis; and translating the BOP assembly along the BOP axis using the linear actuator to install the BOP assembly on the well. The well is a slanted well, for example, inclined at all angles up to and including vertically oriented wells.

These and other aspects of the device and method are set out in the claims, which are incorporated herein by reference.

BRIEF DESCRIPTION OF THE FIGURES

Embodiments will now be described with reference to the figures, in which like reference characters denote like elements, by way of example, and in which:

FIGS. 1A-E are a series of side elevation views of a BOP installation and removal device and method of use.

FIG. 2 is a perspective view looking down on the loader, quick connector jib boom, and the attachment portion of the blowout preventer installation and removal device of FIGS. 1A-E.

FIG. 3 is a side perspective view of the BOP rotator portion of the BOP installation and removal device of FIGS. 1A-E.

FIG. 4 is a lower perspective view of a carriage and linear actuator used in the BOP installation and removal device of FIGS. 1A-E.

FIG. 5 is a lower perspective view of the carriage used in the BOP installation and removal device of FIGS. 1A-E, with clamps that hold the BOP removed.

FIG. 6 is a side elevation view of another embodiment of a BOP installation and removal device.

FIG. 7 is a rear elevation view of the device of FIG. 6 viewed down the BOP axis.

DETAILED DESCRIPTION

Immaterial modifications may be made to the embodiments described here without departing from what is covered by the claims.

A blowout preventer (BOP) is a valve at the top of a well that may be closed if the drilling/service crew fears loss of well control. By closing this valve, which is usually operated remotely via hydraulic actuators, the drilling/service crew can maintain control of the reservoir, and procedures can be initiated until it is possible to re-open the BOP and retain pressure control of the formation. BOPs come in a variety of styles, sizes and pressure ratings. Some can effectively close over an open wellbore, while others are designed to seal around tubular components in the well, such as drill pipe, casing. or tubing. Others are fitted with hardened steel shearing “ram” devices that can actually cut through drill pipe. Common BOP types include ram BOPs and annular BOPs, or combinations thereof. Since BOPs are critically important to the safety of the crew, the rig, the wellbore, and the environment, BOPs may be inspected, tested, and refurbished at regular intervals determined by a combination of risk assessment, local practice, well type, and legal requirements. BOPs are installed during the drilling of the wells or during completion and servicing.

Referring to FIGS. 1A-E, a blowout preventer (BOP) installation and removal device 10 is illustrated having a carriage 12, a linear actuator 14, and a rotator arm 16. The carriage 12 is for supporting a BOP assembly 18, the BOP assembly having a BOP centerline axis 20 (FIG. 1A). The BOP assembly 18 may be a single BOP in some cases, or a stack 22 of BOPs 19A, 19B, and 19C, such as in the example shown. One or more pieces of wellhead equipment such as spools 24, collars, valves, or manifolds may be included as part of the BOP assembly 18. More than one type of BOP may be included in assembly 18, such as annular and ram type BOPs.

Referring to FIGS. 1A and 3, the carriage 12 is mounted on linear actuator 14. Linear actuator 14 has a translation axis 26 that is parallel to the BOP centreline axis 20 in use. Actuation of the linear actuator 14 will translate the BOP in either direction along BOP centreline axis 20. The carriage is mounted to the linear actuator 14 via one or more rails, for example, rails 28 that are mounted to linear actuator 14 for engagement by followers such as rollers 30 on arms 32 of a carriage frame 34. The frame 34 and rails 28 may collectively have the form of an extension ladder as shown. Referring to FIG. 5, actuator 14 may include a suitable drive unit such as a mechanical actuator. The mechanical actuator may be a screw jack with a driver 36 connected between carriage frame 34 and rails 28. In the example shown, driver 36 has a drive piston 38 that is pivotally mounted to a mounting part 40 on carriage frame 34. Driver 36 is mounted to reciprocate within a cylinder 41 pivotally mounted to a rail frame 29 via a mounting part 43. To make actuator 14 more compact in the example shown, an arm travel path is defined by aligned cutouts 42 in rungs 44 forming part of rail frame 29. In the example shown driver 36 is mounted centrally between rails 28, though such is not required. More than one driver 36 may be provided.

Referring to FIGS. 3 and 5, the rotator 16 is mounted to the carriage 12 and connects to the BOP 18 (FIG. 3) for rotating the BOP 18 about the BOP centerline axis 20. The rotator 16 may comprise one or more levers, for example a mechanical actuator such as a screw jack with a driver 45 connected to lever arm 46, the one or more levers being mounted on the carriage 12 and connected in use to the BOP 18, using, for example, one or more flanges 48 which preferably connect to the BOP off the BOP centerline axis 20 using for example, conventional bolts (not shown) that pass into openings on a collar of the BOP (FIG. 3). The lever arm 46 may connect to the BOP at any suitable location, preferably using connection points already on the BOP. A suitable power source such as driver 45 may cause extension and retraction of a piston 50 in a cylinder 52 of driver 45 to impart a lateral force on lever 46 and hence BOP 18 to rotate BOP 18 about axis 20. Cylinder 52 may be mounted on a mounting lug 54 on carriage frame 34. More than one driver 45 may be used.

Referring to FIGS. 1A and 4, the carriage 12 may have one or more BOP mounting parts, such as one or more collars 56 and 58. The collars 56 and 58 partially or fully encircle the BOP at suitable points on the BOP. Collars 56 and 58 are coaxial with BOP centerline axis 20 and form a seat for one or more annular flanges 60, 63, (collar 56) and 61-62 (collectively collar 58) of the BOP assembly 18 (FIG. 1A). In the example shown, both clamping collars 56 and 58 are made up of two half clamping collars 64 secured around BOP 18 by coupling corresponding clamping flanges 66 together using a suitable mechanism such as bolting or cam operated latches (not shown) through bolt holes 68 (FIG. 4). Each clamping collar 56 or 58 may include one or more axial facing shoulders 70 for forming a respective seat for BOP 18. Collars 56 and 58 align the BOP 18 so that the BOP centerline axis 20 is parallel with translational axis 26 thus permitting lateral force imparted upon BOP by rotator 16 to rotate the BOP 18 about axis 20 (FIG. 1A).

Referring to FIGS. 1B and 2, the linear actuator 14 may be mounted on a loader mounting part, such as a frame or quick connector jib boom 74. A pivot actuator 72 may be connected to pivot the linear actuator 14, relative to the jib boom 74, about a pivot axis 76 that is perpendicular to translational axis 26. Pivot actuator 72 may include a suitable drive unit such as a mechanical actuator such as a screw jack with a driver 78 connected between a cylinder mounting clevis 80 and rail frame 29. In the example shown, actuator 78 has a drive actuator rod 79 pivotally mounted to a clevis 81 of a bellcrank 82, which is pivotally mounted at intermediate vertex 85 to frame member 74 with the lower leg 83 of bellcrank 82 affixed to rail frame 29. Actuator rod 79 is mounted to axially reciprocate within a cylinder 84 pivotally mounted to clevis 80. As shown, more than one actuator 78 may be used (FIG. 2).

Referring to FIGS. 1A-E and 2, the BOP handler assembly is mounted onto the jib boom assembly 74. The jib boom assembly 74 may be connected at a work end 90 of a loader arm 86 of a loader 87. Boom 74 may be available on the market from several different manufacturers. The loader 87 may have one or more suitable adapters 88 for quickly connecting jib boom assembly 74 to loader arm 86 (FIG. 2). In the example shown, boom 74 extends from a main quick connector jib boom lifting member to a backplate 92 which is mounted to loader arm 86. A platform 99 is provided to pivotally mount the linear actuator 14. Frame 99 may also mount the pivot actuator 72. Platform 99 may be supported by the boom 74 via a suitable mounting mechanism, such as bars 101 (three shown, though there may be more) that extend from boom 74 and are secured to platform 99 via clevis lugs 95 or other suitable attachment mechanisms extended from platform 99. Boom 74 may be reinforced with one or more flanges 91 extended between boom 74 and backplate member 92. In the example shown, the pivotal axis 76 of the linear actuator 14 about the boom 74 is normally horizontal or close to horizontal to a ground surface 93 below the loader 87 during operation (FIG. 1B).

Referring to FIGS. 1A-E, a method is illustrated of using the BOP installation and removal device 10 to install and remove BOP assembly 18 on a well 94. A first stage involves aligning the BOP axis 20 with a well axis 96. A loader 87 with the installation and removal tool 10 mounted and carrying the BOP 18 approaches the well 94 (FIG. 1A). In FIG. 1A, the loader 87 is positioned such that the BOP axis 20 and the well axis 96 are both located in a plane, represented by the plane of the page and being perpendicular to the ground surface 93 and parallel with a loader forward and backward direction of travel 97. Once positioned over the well 94, pivot actuator 72 may be activated to pivot carriage 12 downwards for alignment of BOP centerline axis 20 with the well centerline axis 96 (FIG. 1B).

A second stage involves translating the BOP assembly 18 along the BOP axis 20 using the linear actuator 14 to install the BOP assembly 18 on the well 94. In the slant well example shown, rough axial translation of BOP 18 along axis 20 may first be accomplished by lowering the loader arm 86 (FIGS. 1B-C). Such translation may be aided by maintaining the quick connector jib boom frame 74 parallel to the ground 93 or horizontal during arm height adjustment, since loader arm 86 will swing along a circular path that is not precisely equivalent to a straight line along axis 96. For such height adjustment to be most effective for rough axial translation, loader arm 86 may be initially raised to a position such that a swing path tangent 77 defined at work end 90 of arm 86 is parallel with well axis 96.

Once the well 94 and BOP centerline axes have been and axially aligned, linear actuator 14 may be used to advance the BOP 18 along axis 96 to position BOP 18 close to well 94 (FIG. 1D). Then, rotation of BOP 18 about centerline axis 20 may also be carried out at this time using rotator 16 as required to align flange bolts 98 with corresponding holes (not shown) in a lower BOP mating flange 100. Once rotationally and axially aligned, BOP 18 may be advanced, axially, to place lower BOP flange 100 into contact with the surface of the wellhead flange of wellhead 94, then nuts 102 may be used to secure BOP 18 to well 94. Once secured, components 56 and 58 may then be removed, BOP 18 may be separated from carriage 12, and device 10 may be retracted and removed in order to leave a completed wellhead BOP assembly 104 as shown.

On completion of the drilling completion or servicing of the well the BOP may be removed and stored for transportation to the next job. The removal procedure may comprise the reverse of some or all steps of the installation procedure. The loader 87 is positioned with the BOP axis 20 aligned in the same vertical plane as the well axis 96. The carriage 12 is positioned, using pivot actuator 72, over the BOP 18 using the reverse of the installation. Members 56 and 58 are installed to secure the BOP 18. The nuts 102 are removed to allow separation of the BOP 18 from the well 94 along the axis 96 of the well. The BOP is moved off the flange bolts 98 along axis 26 by the linear actuator 14. When the BOP is released from the well 94, the loader 87 may transport the BOP to storage on the rig. The BOP installation and removal device may also have fixtures on the carriage to allow it to be used to assemble or dismantle the well head on well 94.

Screw jacks are one type of mechanical actuator that may be used to drive parts of device 10 relative to other parts of device 10. For example, screw jacks may be used for each rotator and linear actuator in device 10. Screw jacks provide a mechanical advantage with, in some cases, several stages of worm drives. The mechanical advantage provides a force advantage as well as an actuator position locking effect, when the actuator is stationary that improves the safety of use of device 10. Various other mechanical actuators may be used that may incorporate a gearbox or transmission between a driver and a power source. In other cases, a source of hydraulic power may be used to drive parts, such as hydraulic arms instead of arms 36 of device 10. Locking valves may be used with hydraulic arms to permit the locking of the arm in a particular position during operation. Hydraulic power from the loader itself or a separate power source may be used. One or both hydraulic and non-hydraulic power sources may be used for one or more or all components of device 10. For example, a mechanical actuator may be powered by a suitable power source, such as an electric motor. Power supply for and the control of actuators on this equipment may be Hydraulic, Hydro-Mechanical, Electro-Mechanical, Electro-Hydro-Mechanical or Manual-Mechanical and provided by remote sources, on-board mounted sources, or manually, whichever is more practical and convenient for a given application.

Referring to FIG. 1A, a controller 49 may be provided for manual or automatic control. Controller 49 may be connected, for example, wired or wirelessly as shown, to send control signals to one or more components of the BOP installation and removal device 10. For example, controller 49 may send control signals to one or more respective transceivers (not shown) individually or collectively associated with the rotator, pivot actuator, and linear actuator. In some cases, the loader 87 itself may be operated by the controller 49. The controller 49 may also receive feedback from the device 10, for example in the form of actuator positions or other sensor readings. The controller 49 may take a variety of forms, for example a purely hydraulic system or a mixed electrical and hydraulic system. Remote radio control may be used. The controller 49 may be operated from the loader 87 or by a user outside the loader 87 as shown. Controller 49 may be manually operated or automatically operated, for example, according to a series of instructions written in a computer program stored on a computer readable medium and run by a processor. Alternatively, controller 49 may be connected umbilically to loader 87 by electrical, hydraulic, or mechanical control lines, and may be suspended from a point on loader 87 as a pendant control box.

Although use on a slanted well is shown, use on vertical and other wells is contemplated. A loader includes an excavator, a tracked or wheeled mover, a skid-steer, telehandler, BOBCAT™, tractor, or other mover with a powered arm for loading. One or more sensors (not shown) may be used for detecting the positioning or approach of BOP 18 at any stage of the process, and in some cases automatically adjusting the approach. Referring to FIG. 5, one or more tabs 51 may be provided on rail frame 29 for mating with corresponding tab receivers 53 on boom 74 for locking the device 10 in a folded position for example, when not in use. In one embodiment, the device 10 forms a multi-axial BOP handler.

Components 56 and 58 represent one example of how the carriage 12 receives a BOP assembly 18. Other examples of a suitable carriage 12 include an encircling frame with arms laterally extended against various points about BOP 18. Straps, chains, or other fasteners may be used to secure the BOP to the carriage 12. Magnets may be used in some cases. BOP 18 may be secured to carriage 12 by threaded points in some cases. Thus, various mechanisms could be used to mount the BOP assembly on the carriage 12.

Referring to FIGS. 6 and 7, another embodiment of a BOP installation and removal device 10 is illustrated. Device 10 has a pivot actuator 72 that comprises a screw jack 75 pivotally mounted to both platform 99 and linear actuator 14. Linear actuator 14 is also pivotally mounted to platform 99 as shown. Thus, when screw jack 75 is extended or retracted, linear actuator 14 pivots downward or upward, respectively. Referring to FIGS. 6 and 7, another embodiment of a BOP installation and removal device 10 is illustrated. Device 10 has a pivot actuator 72 that comprises a screw jack 75 pivotally mounted to both platform 99 and linear actuator 14. Linear actuator 14 is also pivotally mounted to platform 99 as shown. Thus, when screw jack 75 is extended or retracted, linear actuator 14 pivots downward or upward, respectively. In some cases, pivot actuator 72 may comprise a hub mounted motor. Other arrangements and power sources may be used. The rotator 16 may comprise a driver 45 pivotally connected to a drive plate 47 instead of lever arm 46. Drive plate 47 may be a ring as shown and that connects to lugs (not shown) on BOP 18.

In some embodiments, carriage 12 comprises rails 28 that connect to followers or rails on linear actuator 14 for translation.

In the claims, the word “comprising” is used in its inclusive sense and does not exclude other elements being present. The indefinite articles “a” and “an” before a claim feature do not exclude more than one of the features being present. Each one of the individual features described here may be used in one or more embodiments and is not, by virtue only of being described here, to be construed as essential to all embodiments as defined by the claims. 

The embodiments of the invention in which an exclusive property or privilege is claimed are defined as follows:
 1. A blowout preventer (BOP) installation and removal device, comprising: a carriage for supporting a BOP assembly, the BOP assembly having a BOP axis; the carriage being mounted on a linear actuator that has a translation axis that is parallel to the BOP axis; and a rotator mounted to the carriage and connectable to the BOP for rotating the BOP about the BOP axis.
 2. The BOP installation and removal device of claim 1 mounted on a loader arm of a loader.
 3. The BOP installation and removal device of claim 1 in which the linear actuator is mounted on a loader mounting part, with a pivot actuator connected to pivot the linear actuator, relative to the loader mounting part, about a pivot axis perpendicular to the translation axis.
 4. The BOP installation and removal device of claim 3 in which the loader mounting part comprises a quick connector jib boom.
 5. The BOP installation and removal device of claim 4 in which the loader mounting part is mounted on a loader arm of a loader.
 6. The BOP installation and removal device of claim 5 in which the pivot axis is horizontal to a ground surface below the loader.
 7. The BOP installation and removal device of claim 5 in which the quick connector jib boom is positioned above the linear actuator in use.
 8. The BOP installation and removal device of claim 1 in which the carriage further comprises one or more clamping collars that are coaxial with the BOP axis and form a seat for one or more annular flanges of the BOP assembly.
 9. The BOP installation and removal device of claim 1 in which the carriage is mounted to the linear actuator via one or more track rails.
 10. The BOP installation and removal device of claim 1 in which one or more of the linear actuator and rotator each comprise a screw jack.
 11. The BOP installation and removal device of claim 1 further comprising a controller connected to send control signals to one or more components of the BOP installation and removal device.
 12. A combination comprising a BOP assembly mounted to the carriage of the BOP installation and removal device of claim 1 with the rotator connected to the BOP and the BOP axis parallel to the translation axis.
 13. A method of using the BOP installation and removal device of claim 1 further comprising installing and removal a BOP assembly on a well.
 14. The method of claim 13 in which installing further comprises: aligning the BOP centerline axis with a well centerline axis; and translating the BOP assembly along the BOP axis using the linear actuator to install the BOP assembly on the well.
 15. The method of claim 14 further comprising, before translating, rotating the BOP using the rotator to align studs on a wellhead with lower flange mounting holes on the BOP.
 16. The method of claim 13 in which the well is a slanted well.
 17. A blowout preventer (BOP) installation and removal device, comprising: a BOP assembly mounted on a carriage, the BOP assembly having a BOP axis; the carriage being mounted on a linear actuator that has a translation axis that is parallel to the BOP axis; a rotator mounted to the carriage and connected to the BOP for rotating the BOP about the BOP axis; and the linear actuator being mounted on a loader mounting part, with pivot actuator connected to pivot the linear actuator, relative to the loader mounting part, about a pivot axis perpendicular to the translation axis.
 18. The BOP installation and removal device of claim 17 in which the loader mounting part comprises a quick connector jib boom.
 19. The BOP installation and removal device of claim 18 in which the quick connector jib boom is secured to a loader arm. 